Stamford UC22-27 manual

UC AC GENERATORS Installation, Servicing and Maintenance

English Original Instructions

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Table of Contents 1.

FOREWORD................. FOREWORD............................ ...................... ...................... ...................... ...................... ...................... ...................... ...................... ...................... ...................... ...........

1

2.

SAFETY PRECAUTIONS PRECAUTIONS ...................... ................................. ...................... ...................... ...................... ...................... ...................... ...................... ................... ........

3

3.

STANDARDS STANDARDS ...................... ................................. ...................... ...................... ...................... ...................... ...................... ...................... ...................... ...................... ................ .....

7

4.

INTRODUCTION INTRODUCTION ...................... ................................. ...................... ...................... ...................... ...................... ...................... ...................... ...................... ..................... ..........

9

5.

AUTOMATI AUTOMATIC C VOLTAGE VOLTAGE REGULAT REGULATORS ORS (AVR) (AVR) ........ ............ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ...... ..

13

6.

APPLICA APPLICATION TION OF THE GENERAT GENERATOR OR ........ ............ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ....

19

7.

INSTALL INSTALLATIO ATION N INTO THE GENERATI GENERATING NG SET...... SET.......... ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ....

25

8.

SERVICE & MAINTENANCE........ MAINTENANCE.................. ..................... ...................... ...................... ...................... ...................... ...................... ...................... ................ .....

33

9.

FAULT FINDING......................... FINDING.................................... ...................... ...................... ...................... ...................... ...................... ...................... ...................... ................. ......

37

10. PARTS IDENTIFICATION IDENTIFICATION ..................... ................................ ...................... ...................... ...................... ...................... ...................... ...................... ................. ......

43

11. SPARES AND AFTER SALES SERVICE ..................... ................................ ...................... ...................... ...................... ...................... ............... ....

49

12. END OF LIFE DISPOSAL............. DISPOSAL........................ ...................... ...................... ...................... ...................... ...................... ...................... ...................... ............... ....

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Foreword

1.1

The Manual This manual contains guidance and instructions for the Installation, Servicing and maintenance of the generator. generator. Before operating the generator/alternator, read this manual and make sure that all personnel who who work work on the the equi equipm pmen entt have have acce access ss to the the manu manual al and and all all addi additi tion onal al docu docume ment ntat atio ion n suppli supplied ed with with it. Misuse Misuse and failur failure e to follow follow the operat operating ing instru instructi ctions ons may invalid invalidate ate the product warranty and lead to potential accidents. The manual should be considered as part of the product and should remain with the product. Make sure that the manual is available to all users throughout the life of the product. The manual is written for skilled electrical and mechanical technicians and engineers, who have prior knowledge and experience of generating equipment of this type. If in doubt, please seek expert advice or contact your local Cummins Generator Technologies subsidiary.

NOTICE Due to our policy of continuous improvement, details in this manual were correct at time of  going to print. Information included must therefore not be regarded as binding. Please visit www.cumminsgeneratortechnologies.com for www.cumminsgeneratortechnologies.com  for latest documentation.

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Safety Precautions

2.1

Warnings & Notices used in this manual Notes, Cautions and Warnings are used in this manual to emphasise important or critical instructions:

DANGER Danger refers to immediate hazards which WILL result in severe personal injury or death.

WARNING Refers to a hazard or unsafe method or practice which CAN result in severe personal injury or  possible death.

CAUTION Refers to a hazard or unsafe method or practice which can result in product damage or personal injury.

NOTICE Used to convey, or draw attention to additional information or explanations.

2.2

Skill Requirements of Personnel Service and maintenance procedures should only be carried out by experienced and qualified engineers, who are familiar with the procedures and the equipment.

2.3

Personal Protective Equipment (PPE) Ensure that all personnel operating, servicing, maintaining or working near this equipment are wearing appropriate Personal Protective Equipment (PPE) including eye and ear protection and are fully aware of the emergency procedures in case of accidents.

2.4

Noise Generators emit noise. Ensure appropriate ear protection is worn at all times. Maximum A weighted emissions levels may reach 104db (A) contact site for application specific details.

2.5

Electrical Equipment  All electrical equipment can be dangerous if not operated correctly. Always service and maintain the generator in accordance with this manual. Always use genuine ‘STAMFORD’ replacement parts.

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WARNING Do not handle PMG's if you have mechanically implanted devices; ie pacemakers.

2.6

Lock Out/Tag Out Before any maintenance work on the generator is carried out, please ensure it is isolated from any source of mechanical and electrical energy. It is suggested that a suitable lock-out/tag out process is adopted.

2.7

Lifting

WARNING The lifting points provided are designed for lifting the generator only. Do not lift the Generating Set by the generator’s lifting points.

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2.8

Generator Operating Areas

Operating in hatched areas or directly in-line with any air inlet/outlet should be avoided where possible. Always wear suitable PPE when working in these areas.

WARNING Do not place controls within the vicinity of the air inlet/outlet of the machine and ensure personnel are restricted from these areas during operation. In the event of catastrophic failure, machine parts may exit these areas

2.9

Warning Labels Warning labels are affixed to the generator. These must be visible at all times.  As we expect the set builder to paint the generator in his own livery, a second set of labels can be found in a wallet attached to the generator. Use the labels as per the instructions printed on the reverse of the labels.

NOTICE If removed or painted over, it is the genset manufacturer's responsibility to reaffix warning symbols onto the generator 

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Standards STAMFORD AC generators meet the relevant parts of national and international standards pertaining to generators. The generator must be operated within the limits laid down in the relevant standards and within the parameters on the generator rating plate. Marine generators meet the requirements of all the major marine classification societies.

3.1

European Directives: EC Declaration of Conformity

Each generator is supplied with an ‘EC Declaration of Conformity’ in accordance with the relevant EU directives designed for incorporation into an electricity generating set and is CE marked. Our authorized representative in the Community is Mr Jeffrey Matthews, Director, Engineering, Cummins Generator Technologies Ltd.  All STAMFORD generators meet the following Standards and Directives: Directives: ·

2004/108/EC EMC Directive

·

2006/95/EC Low Volts Directive

·

2006/42/EC Machinery Directive

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Standards: ·

  EN 61000-6-1

·

  EN 61000-6-2

·

  EN 61000-6-4

·

EN ISO 12100-1

·

EN ISO 12100-1

·

EN ISO 14121-1

·

  EN 60034-1

·

 BS ISO 8528-3

·

  BS5000-3

NOTICE Once the generator is built into a generating set, it is the responsibility of the generating set manufacture to ensure that the generating set complies with the relevant EC Directives.

3.2

Additional Information for EMC Compliance STAMFORD generators are designed to meet the ‘industrial’ emissions and immunity standards. Where the generator is required to meet the residential, commercial and light industrial emissions and immunity standards reference must be made to document reference N4/X/011. This publication outlines the additional equipment that may be required. The installation ‘earth/ground’ arrangements require the connection of the generator frame to the site protective earth conductor using a minimum lead length. Maintenance and servicing with unauthorised parts, not of STAMFORD brand, will invalidate Cummins Generator Technologies from any liability for EMC compliance. Installation, maintenance and servicing are carried out by adequately trained personnel fully aware of the requirements of the relevant EC directives.

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Introduction

4.1

General Description - UC The UC22/27 range of generators is of brushless rotating field design, available up to 660V/50Hz (1500 rpm) or 60Hz (1800 rpm), and built to meet BS5000 Part 3 and international standards.  All the UC22/27 range are self-excited with excitation power derived from the main output windings, using either the SX460/SX440/SX421 AVR. The UC22 is also available with specific windings and a transformer controlled excitation system.  A permanent magnet generator (PMG) powered excitation system is available as an option using either the MX341 or MX321 AVR.

4.2

Serial Number Location Each generator has a unique serial number stamped into the upper section of the drive end of  the frame.

The serial number is also shown on the STAMFORD nameplate.  A typical serial number looks like: A09B219907 Year of manufacture is depicted by the first two numbers: ie example shows year of  manufacture as 2009.

4.3

Rating Plate The generator has been supplied with a self-adhesive rating plate label to enable fitting after  final assembly and painting.

CAUTION Do not exceed the parameters marked on the rating plate, as this can cause the machine to overheat, which can lead to catastrophic failure and risk of personal injury.

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4.4

Product Authentication The STAMFORD high security, anti-counterfeit hologram is located on the Tracking Label. Visual confirmation of genuine STAMFORD AC generator is achieved by viewing the flashing 3D hologram dots from differing angles – a flashlight may assist this - then verifying the machine identity online at www.stamford-avk.com/verify. Keying in the unique 7 character hologram machine identity online provides further confirmation that the machine is genuine.

FIGURE 1.

GLOBAL STAMFORD AC GENERATOR NAMEPLATE, COMPRISING RATING PLATE AND TRACKING LABEL

FIGURE 2.

3D HOLOGRAM

4.5

Self-Excited AVR Controlled Generators

4.5.1

Main Stator Powered AVR The main stator provides power for excitation of the exciter stator via the AVR, which is the controlling device governing the level of excitation provided to the exciter stator. The AVR responds to a voltage-sensing signal derived from the main stator winding. By controlling the low power of the exciter stator, control of the high power requirement of the main rotor is achieved through the rectified output of the exciter rotor.

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No.

Description

No.

Description

1

Main rotor

5

AVR

2

Rotating diodes

6

Main stator  

3

Exciter rotor

7

Output

4

Exciter stator

8

Shaft

4.5.2

Transformer Controlled Generators The main stator provides power for excitation of the exciter stator via a transformer rectifier unit. The transformer combines voltage and current elements derived from the main stator output to form the basis of an open-loop control system, which is self regulating in nature. The system inherently compensates for load current magnitude and power factor and provides short circuit maintenance in addition to a good motor starting performance. Three-phase generators normally have a three-phase transformer control for improved performance with unbalanced loads but a single-phase transformer option is available. No accessories can be provided with this control system.

4.6

Separately Excited AVR Controlled Generators

4.6.1

Permanent Magnet Generator (PMG) excited - AVR controlled generators The Permanent Magnet Generator (PMG) provides power for the excitation of the exciter stator  via the Automatic Voltage Regulator (AVR) which is the controlling device governing the level of  excitation provided to the stator field. The AVR responds to a voltage-sensing signal derived, via MX321 only "where fitted", from the main stator winding. By controlling the low power of the exciter stator, control of the high power requirerment of the main rotor is achieved through the rectified output of the exciter rotor.

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No.

Description

No.

Description

No.

Description

1

Main rotor

5

PMG stator

9

2

Rotating diodes (if fitted)

6

Exciter stator

10 Output

3

Exciter rotor

7

AVR

11 Shaft

4

PMG rotor

8

Isolating transformer (if fitted)

12

Main stator  

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Automatic Voltage Regulators (AVR) Cummins Generator Technologies offer a selection of Automatic Voltage Regulators designed and built to achieve maximum performance from the range of STAMFORD brushless AC generators. Both self excited and separate permanent magnet excited types are available, with a choice of specifications. All STAMFORD AVR’s are encapsulated to provide protection against moisture, salt and sand in the atmosphere, and are mounted on anti-vibration mounts for added mechanical protection. Each AVR offers a range of features dependent upon the AVR type and design. Models are available to suit most customer requirements from simple, low-cost analogue through to sophisticated digital control. STAMFORD AVRs share several common features: All AVRs can be fitted with a ‘Hand Trimmer’ for fine control of the generator voltage, all have ‘Under-Frequency Roll-Off’ (UFRO) for reducing generator voltage proportional to speed and all can be equipped for parallel operation with other generators.

5.1

Self Excited Types  AVR’s for self excited generators receive their power direct from the generator output terminals, and control generator output voltage through continual automatic adjustment of the exciter and main rotor field strengths.

5.1.1

AS440 The AS440 is the standard AVR offered with generators up to approximately 800kVA, achieving voltage regulation of ±1.0%*. The design employs surface mount technology, custom mouldings and heatsink to produce a compact AVR assembly. The AVR retains an auxiliary winding control features from earlier models in order to provide support for obsolete generator products.

5.2

Permanent Magnet Generator (Pilot) Types For the ultimate in control, an AVR designed to operate with the permanent magnet generator  (PMG) system is often specified. In this design, the AVR receives its power from a separate source in the form of a small PMG, mounted on the main generator shaft. The advantage of this arrangement is that the AVR power source is not affected by sudden loads applied to the generator, hence the excitation remains at full capability, providing superior motor starting and short circuit performance. By having a completely electrically isolated control system the generator is better able to meet the more stringent EMC performance requirements.

5.2.1

MX341 The MX341 achieves voltage regulation of ±1.0%* and protection against sustained overexcitation is standard on this AVR. In addition to the standard under-frequency protection feature, this AVR can be adjusted to assist the engine to recover speed when large loads are applied in a single step. Soft-start circuitry is included to provide a smooth controlled build up of  generator output voltage.

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5.2.2

MX321 The MX321 has all the features of the MX341, additionally achieving voltage regulation of  ±0.5%* with three-phase RMS sensing, built in overvoltage protection and optional short-circuit current level adjustment. The combination of PMG and the RMS sensing makes an ideal arrangement for supplying nonlinear loads such as supplies for computers and variable speed motors etc

5.3

AVR Features Summary STAMFORD AC generators can be configured to meet practically every application requirement. This chart summarises the main features of the AVR product ranges.

AVR

Type

Self Excited

PMG Excited

Model

AS480

AS440

MX341

MX321

MA330

DM110

Remote Voltage Adjust

A

A

A

A

A

A

Under-Frequency Protection

A

A

A

A

A

A

Paralleling

A

A

A

A

A

A

A

A

A

A

(3)

A

A

A

A

A

A

A

A

A

A

A

A

Three-Phase RMS Sensing

A

A

A

Over-Voltage Protection

A

A

A

Variable Dwell

A

A

 Accessory Input (for PFC etc.)  Adjustable UFRO 'Slope'

Feature

Short-Circuit Maintenance

(1)

110 ... 120VAC Operation

(2)

A

Soft-Start Ramp

Excitation Limiting Current Limiting

A A

Full Digital Control ·

5.4

A

A

 A = Available

·

(1) By add-on optional Excitation Boost System

·

(2) By add-on optional special link wire

·

(3) Version available with integrated Power-factor control

AVR Usage Summary STAMFORD AC generators can be configured to meet practically every application requirement. This chart summarises the AVR usage in conjunction with the Generator product range.

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Generator Product:

Standard AVR:

Optional AVR:

P0; P1

AS480

UCI22; UCI27; UCD27

AS440

MX341; MX321

UCM22; UCM27

MX341

MX321

HCI4; HCI5; HCKI5

AS440

MX341; MX321

HCM4; HCM5

MX341

MX321

HCI6

MX321

HCM6

MX321

PI7; PE7

MX341

MX321

P80

DM110

MX321

5.5

AVR Accessories  A selection of accessories is available for connection to the AVR to provide the additional functions normally expected in generator installations. Control accessories can be factory fitted or supplied separately for fitting by a competent technician. When supplied separately, the accessory will be provided with fitting and wiring instructions. This chart shows which accessory can be connected to the chosen AVR model. AVR

Accessory

Type

Model

Hand Trimmer (for Remote Voltage  Adjust)

Droop Tranformer (for Paralleling)

Self Excited

AS480

A

A

 AS440

A

A

A

MX341

A

A

A

MX321

A

A

A

MA330

A

A

A

DM110

A

A

(1)

PMG Excited

·

·

5.5.1

Power Factor Controller

Excitation Boost System (for Short-Circuit Maintenance ) A

Low Voltage Current Link/Selector Limiting (for 110 ... Transformers 120VAC Operation) A A

A

 A = Available (1) = Version available with integrated Power-factor control

Hand Trimmer (for remote voltage adjustment)  A hand trimmer can be fitted in a convenient position (typically in the generator set control panel) and connected to the AVR to provide fine adjustment of the generator voltage. The hand trimmer value and the adjustment range obtained is as defined in the Technical Specification. On all AVRs, the hand trimmer is connected to terminals 1;2 after first removing the shorting link.

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5.5.2

Droop Transformer (for parallel operation – generator to generator)  A droop transformer can be fitted in a defined position in the generator main output wiring and connected to the AVR to enable parallel operation with other generators. The adjustment range is as defined in the Technical Specification. On all AVRs, the droop transformer is connected to terminals S1;S2 after first removing the shorting link. The droop transformer MUST be connected in the correct main output terminal for proper operation (details are as shown in the machine wiring diagram).

5.5.3

Power Factor Controller (for parallel operation – generator  to mains utility)  An electronic control module is available for use with the AVR to provide power factor control of  the generator output. The module uses generator voltage and output current as inputs and interfaces with the AVR to ensure the necessary flexibility of the generator excitation and hence control of the exported (or imported) kVAr. This allows full closed-loop control of the generator  power factor at the point of connection into the mains utility. Other features allow the generator  (or generators) to be automatically ‘voltage-matched’ prior to paralleling. This accessory is not available with the AS480 AVR.

5.5.4

Low Voltage Link/Selector (AS480/AS440 AVR only) Both the AS480 and the AS440 AVRs (self excited types) can be configured for low voltage working. For operation between 100Vac and 120Vac the AS480 can be supplied with a special wire link which connects between the generator main terminals and AVR input terminal ‘S1’. In the case of the AS440 AVR, low voltage operation is enabled by fitting a shorting link across terminals ‘La’ and ‘Lb’. In low-voltage operating mode and in both cases the overload performance of the control system is reduced.

5.5.5

Current Limiting Transformers (MX321 AVR only) Generator main output current can be electronically limited by connecting additional current transformers to the MX321 AVR. In any situation where the output current attempts to rises above a preset threshold (set on AVR) then the AVR will reduce the terminal voltage to restore the set current level. For unbalanced loads, operation is based on the highest of the three phase currents.

5.6

AVR Fault Finding WARNING Fault finding procedures present hazards, which can result in injury or death.

Only personnel qualified to perform electrical and mechanical service should carry out these procedures. Ensure engine-starting circuits are disabled before commencing service or  maintenance procedures. Isolate any anti-condensation heater supply.

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NOTICE Before commencing any fault finding procedures examine all wiring for broken or loose connections.

Problem Voltage does not build-up to normal when starting the generator set.

Action

1. Check link K1:K2 on AVR (not AS480) or auxiliary terminals: - Replace if necessary and restart.

2.  MX321 or MX341 only; - Check the output from the PMG, Go to {Checking the PMG}. Voltage builds-up but is at an incorrect value.

1. Check AVR [VOLTS] control potentiometer setting: - Correct if necessary. - Check ‘Hand Trimmer’ if one is fitted - adjust if necessary.

2.   Check generator speed: - Correct if necessary and restart.

3.   Check AVR ‘UFRO’ indicator: - If it is illuminated, Go to {UFRO Setting Procedure}. Voltage is very slow to build up.

1.   Check generator accelerates as expected: - Correct if necessary and restart.

2. MX321 only; Check setting of ramp potentiometer: - Correct if necessary and restart. Voltage rises and remains at a high level.

1.   Check AVR wiring:

Voltage rises to a high level and then falls to a low level.

1.   Check AVR wiring:

Voltage is normal and then falls to a low level while the generator set is running.

1.   Check generator loading:

Voltage is unstable either on no-load or with load.

1. Check that the generator speed is stable:

2.   Check machine Rotating Rectifiers

- Correct if necessary and restart.

2.   Check AVR wiring: 3. Adjust the AVR [Stability] control slowly clockwise until steady. Voltage falls to a low level when load is applied to the generator.

1. Check generator speed is not dropping as load is applied: - Correct if necessary and restart.

2.   Check AVR ‘UFRO’ indicator: - If it illuminates as load is applied, Goto {UFRO Setting Procedure}.

If all the tests and checks listed above fail to locate the generator fault then it must be assumed that the AVR is faulty. There are no serviceable items on the AVR. The AVR should be replaced only by a genuine STAMFORD part.

5.6.1

Checking The PMG (MX341 and MX321 AVRs only) 1. Start the generator set and run it at rated speed.

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2. Measure the voltages at the AVR terminals P2, P3 and P4.These should be balanced and within the following ranges: 50Hz generators: 170 ... 185VAC. 60Hz generators: 200 ... 220VAC. 3. Stop the generator. 4. Measure the PMG winding resistances (at the connections under the PMG cover). These should be balanced and within the following range: 4 pole generators: 2.6 ohms +/-10% 6 pole generators: 5.6 ohms +/-10% 5. Use the results from tests 2) and 3) above together with the table below to identify the fault. PMG Voltages:

Phase/Phase Resistances: Correct

Incorrect

Balanced

No fault with PMG

Recheck resistances

Unbalanced

Connector ?

Change PMG Stator  

Balanced

Change PMG Rotor

Change PMG Stator  

Unbalanced

Connector ?

Change PMG Stator  

Correct

Low

5.6.2

UFRO Setting Procedure 1. Stop the generator. 2. Check that the AVR UFRO selection link is set for the required 50Hz or 60Hz operation. 3. Start the generator set and run it at rated speed. 4. If the voltage is now correct and the UFRO indicator is not illuminated, return to the fault finding procedure. 5. If the UFRO indicator is illuminated, continue as follows. 6. Adjust the [UFRO] control fully clockwise. 7. Set the generator speed at 95% of rated speed. For 50Hz installations: 1425rpm or 47.5Hz For 60Hz installations: 1710rpm or 57.0Hz 8. Adjust the [UFRO] control slowly counter-clockwise until the UFRO indicator just illuminates.Return the control slightly clockwise until the indicator is just extinguished. 9. The UFRO setting is now correct - return to the fault finding procedure.

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Application of the Generator  It is the customers' responsibility to ensure that the sizing selection of the generator is suitable for the final application.

CAUTION Overloading the generator may lead to catastrophic failure.

6.1

Environmental Protection STAMFORD generators are protected to IP23. IP23 is not adequate protection for use outdoors without additional measures. Ambient Temperature